WO2004041534A1 - Structure de stratifie thermoplastique avec coeur en placage de bois - Google Patents

Structure de stratifie thermoplastique avec coeur en placage de bois Download PDF

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Publication number
WO2004041534A1
WO2004041534A1 PCT/US2003/028795 US0328795W WO2004041534A1 WO 2004041534 A1 WO2004041534 A1 WO 2004041534A1 US 0328795 W US0328795 W US 0328795W WO 2004041534 A1 WO2004041534 A1 WO 2004041534A1
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WO
WIPO (PCT)
Prior art keywords
laminate
layer
sheet
sheets
thermoplastic
Prior art date
Application number
PCT/US2003/028795
Other languages
English (en)
Inventor
Richard C. Wilson
Original Assignee
Wilson Richard C
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Wilson Richard C filed Critical Wilson Richard C
Priority to AU2003272364A priority Critical patent/AU2003272364A1/en
Publication of WO2004041534A1 publication Critical patent/WO2004041534A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/08—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the cooling method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/584—Scratch resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/738—Thermoformability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2327/00—Polyvinylhalogenides
    • B32B2327/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2333/00—Polymers of unsaturated acids or derivatives thereof
    • B32B2333/04—Polymers of esters
    • B32B2333/12—Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2355/00—Specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of index codes B32B2323/00 - B32B2333/00
    • B32B2355/02—ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2369/00—Polycarbonates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2375/00—Polyureas; Polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • the invention relates to a thermoplastic-wood laminates, and a method for making such thermoplastic laminates.
  • Decorative panels, walls, countertops, furniture, and architectural building components that incorporate a real wood veneer remain in great demand.
  • the prior art teaches the use of decorative polymeric veneers applied to wood or medium-density fiberboard (MDF) substrates that simulate the look of real wood. While such polymeric veneers typically perform significantly better in such environments than real wood veneers, a need continues to exist to improve the performance of such veneered products, including the reduction of a "telegraphing" by the veneer of substrate features, including glue lines, dirt, and other substrate surface imperfections.
  • MDF medium-density fiberboard
  • a thermoplastic laminate includes a top layer selected from the group consisting of at least one sheet of a first acrylic material, and a sheet of a first polyvinyl chloride material having an upper face to which a scratch-resistant coating is applied.
  • the laminate of the invention further includes a first intermediate layer formed of a sheet of a first polycarbonate material, a second intermediate layer formed of a cellulose-based material, such as wood, cloth, or printed paper, and a bottom layer selected from the group consisting of a sheet of a second polycarbonate material, at least one sheet of a second polyvinyl chloride material, and at least one sheet of an acrylonitrile-butadiene- styrene (ABS) material.
  • a layer of a polyurethane adhesive is disposed between both the first intermediate layer and the second intermediate layer, and the second intermediate layer and the bottom layer.
  • thermoplastic laminate incorporates a real or simulate wood core (or another image printed on the cellulosed-based material in compatible ink, as desired) while featuring the enhanced impact strength of both the top layer and the upper polycarbonate layer, and either the increased wear resistance of the top layer's hardcoated PVC sheet, or the "repairability" and optical performance of the top layer's acrylic sheet.
  • the top layer may advantageously include additives that enhance the acrylics performance such as UV inhibitors or colorants, pigments, decorative metal flakes, abrasion resistant additives, or other materials that can alter the appearance of the top acrylic layer and/or provide the laminate's upper surface with a desired set of characteristics, such as impact and wear resistance, opacity, and modification or enhancement of the "image" provided by the second intermediate layer.
  • additives that enhance the acrylics performance such as UV inhibitors or colorants, pigments, decorative metal flakes, abrasion resistant additives, or other materials that can alter the appearance of the top acrylic layer and/or provide the laminate's upper surface with a desired set of characteristics, such as impact and wear resistance, opacity, and modification or enhancement of the "image" provided by the second intermediate layer.
  • the invention contemplates providing a selected surface finish to the top layer, such as a textured or patterned surface finish, whereby the second intermediate layer's "image" can be similarly modified or enhanced.
  • the bottom layer features at least two sheets of either the PVC or ABS materials, each sheet preferably is of substantially the same thickness.
  • the use of multiple plies in the bottom layer helps reduce "telegraphing" of substrate surface irregularities and imperfections, thereby improving the aesthetic qualities of the resulting veneered product incorporating the thermoplastic laminate of the invention.
  • the sheet material is preferably characterized by a relatively-low loading of plasticizers to thereby reduce gas-off during heat-and-pressure lamination.
  • Additives such as UV inhibitors may be included to improve or otherwise alter the performance of the PVC material, and each such PVC sheet is preferably provided with a matte finish to prevent bubble formation by trapped gases during hot pressing.
  • a method of making a substantially-rigid composite laminate includes stacking or "booking" several layers of selected thermoplastic polymers between a designated pair of press plates, and urging the layers together under suitable heat and pressure, for example, by hot pressing between the heated platens of a hot press, at a selected platen temperature, for a period of time sufficient to achieve cross-linking of the polymers of the several contiguous layers and their constituent sheets, and the curing of the layers of polyurethane adhesive.
  • Figure 1 is a sectional view of first exemplary thermoplastic laminate in accordance with the invention.
  • Figure 2 is a sectional view of second exemplary thermoplastic laminate in accordance with the invention.
  • Figure 3 is a sectional view of third exemplary thermoplastic laminate in accordance with the invention.
  • Figure 4 is a sectional view of several "books" stacked within a hot press during an exemplary method of making several of the first exemplary thermoplastic laminates;
  • Figure 5 is an enlarged sectional view showing one of the "books" of
  • thermoplastic laminates 10,12,14 incorporating either a wood or other cellulose-based intermediate "image” layer are illustrated in partial section in Figures 1 -3.
  • Each of the exemplary thermoplastic laminates in accordance with the invention includes a thermoplastic top layer 16, a thermoplastic first intermediate layer 18, the cellulose-based image layer 20, and a thermoplastic bottom layer 22.
  • the first and second laminates 10,12 each has a top layer 16 formed of one or more sheets of a polymethylmethacrylate (PMMA) material that, depending upon the desired characteristics of the upper surface 26 of the laminate 10,12, may be a modified acrylic, or impact acrylic.
  • PMMA polymethylmethacrylate
  • the top layer's acrylic material is modified with dibutyl rubber (DR) to thereby improve the layer's impact strength.
  • DR dibutyl rubber
  • the top layer's acrylic material may also be modified, as desired, with additives that enhance other of the layer's performance characteristics, such as UV inhibitors, and/or colorants, pigments, decorative metallic flakes or particles, or other materials that can alter the appearance of the resulting laminate's upper surface 26.
  • the acrylic top layer 16 advantageously features a "repairable" upper surface, inasmuch as the nominally glossy surface finish may be restored as by polishing.
  • An abrasion-resistant coating (not shown) may alternatively be applied to the upper surface 26 of the acrylic sheet.
  • the acrylic top layer 16 preferably has a thickness greater than about 0.005 inches, and less than about 0.025 inches.
  • the top layer's acrylic sheet is perhaps about 0.015 inches thick.
  • the minimum thickness of the acrylic top layer 16 is preferably selected to achieve a desired optical characteristic, for example, depth or "wetness" of image, as when viewing the resulting laminate's upper surface 26.
  • the next layer 18 of the first and second laminates 10,12 of Figures 1 and 2 is formed of a polycarbonate material.
  • the polycarbonate first intermediate layer 18 may have additives such as UV inhibitors that can improve or otherwise alter the performance of the polycarbonate, and a matte finish is preferred.
  • the polycarbonate first intermediate sheet can have a thickness greater than about 0.001 inches, up to about 0.020 inches. In the first laminate 10, the polycarbonate first intermediate layer 18 is perhaps about 0.010 inches thick.
  • the 10,12 is the cellulose-based image layer formed, for example, of a wood veneer, cloth, or paper.
  • the second intermediate layer 20 forms the primary "image" layer of the laminate 10,12.
  • the ink is preferably compatible with the layer of polyurethane adhesive 24 used to bond the polycarbonate first intermediate layer 18 to the second intermediate "image" layer 20.
  • the bottom layer 20 in the first laminate 10, is formed of a single sheet of polycarbonate material, in a thickness ranging from between about 0.001 inches to about 0.250 inches, and preferably between about 0.025 and about 0.250.
  • the bottom layer 20 is formed of one or more sheets or films of a high-impact PVC material (hereafter collectively referred to as "sheets 28" for clarity), in roughly the same thickness at the polycarbonate bottom layer 20 of the first laminate 10.
  • sheets 28 high-impact PVC material
  • the PVC material forming the second laminate's bottom layer 22 can be either rigid or flexible; however, it is preferable to limit the amount of plasticizers used in material compounding prior to extrusion, to thereby reduce gas-off during heat-and-pressure lamination.
  • the PVC bottom layer 22 may likewise include additives such as UV inheritors that can improve or otherwise alter the performance of the layer's PVC material.
  • the PVC bottom layer 22 preferably has a matte finish to prevent bubble formation by trapped gases.
  • the third laminate 14 includes a top layer 16 formed of a single sheet 30 of a PVC material, in a thickness of perhaps about 0.005 inches, as a carrier for the sheet's abrasion-resistant coating 32, such as a glass hardcoat having a nominal thickness of perhaps about 0.001 inches, that is applied to the sheet's upper surface 34.
  • the third laminate's bottom layer 22 is formed of multiple sheets 36 of a high-impact ABS material, preferably of like nominal thickness. Once again, the multiple plies of the ABS material are simply stacked, one atop another, to define the bottom layer 22 of the third laminate 14.
  • the ABS material may be modified with additives to enhance performance, e.g., a flame retardant.
  • the surfaces of the constituent layers and sheets are preferably provided with a desired surface finish.
  • the invention contemplates use, for example, of textured pinch rollers or transfer sheets (not shown) during constituent sheet manufacture/preparation to thereby impart a desired surface finish to the face of a given acrylic, PCV, PC, or ABS constituent sheet, as necessary, thereby obviating any further surface preparation prior to lay up.
  • Other methods for preparing the sheet surfaces prior to booking are also contemplated, including etching and laser scoring, and/or applying a surface charge to the constituent sheets to thereby cause the laid-up sheets to draw closer to one another.
  • the constituent layers 16,18,20,22 are stacked between a pair of polished steel press plates 38 to form a "book 40," whereupon one or more such books 40 are placed/stacked between the platens 42 of a hot press 44.
  • a hot press 44 Preferably, when multiple books 40 are stacked between the platens 42 of a given hot press 44, like layer/book thickness should be used to achieve greater yield uniformity.
  • the stacked books 40 are then hot pressed at a suitable combination of temperatures, preferably ranging from about 240°F to about 330°F, and pressures, preferably ranging from about 50 psi to about 260 psi (or even as high as about 300 psi for particularly thick books 40, or for large stacks of books 40), to cause the constituent layers and sheets of each book 40 to laminate together, i.e, to achieve a cross-linking of their polymers, while the polyurethane adhesive 24 is cured.
  • the time sequence and overall time of a given book 40 in the hot press 44 is dependent upon how fast the combination of temperatures and pressures can be applied and the overall thickness of the book 40 to be laminated.
  • the top layer's upper surface 26 may advantageously be imparted with a desired textured or glossy surface finish, depending upon press plate selection.
  • the invention contemplates use of a suitable release sheet (not shown) may be used to provide the desired surface texture and gloss.
  • the upper press plate 38 used with a given book 40 may itself define a mold so that, during hot pressing, the top layer 16 would assume the design of the mold surface. In this manner, desired surface characteristics and features are readily imparted to the resulting laminate 10,12,14.
  • the laminate 10,12,14 is then cooled to an intermediate temperature that facilitates handling, for example, about 110F°. When this intermediate temperature is achieved, the pressure is released and the laminate removed. Alternately, the laminate 10,12,14 while still hot can be transferred to another press, and a secondary pressure, sufficient to maintain the several constituent layers together, such as 100 psi in the exemplary method, reapplied. The laminate 10,12,14 is then cooled, or permitted to cool, at that second pressure until the temperature of the laminate 10,12,14 falls to the intermediate temperature, at which time the secondary pressure is released.
  • an intermediate temperature that facilitates handling
  • the pressure is released and the laminate removed.
  • the laminate 10,12,14 while still hot can be transferred to another press, and a secondary pressure, sufficient to maintain the several constituent layers together, such as 100 psi in the exemplary method, reapplied.
  • the laminate 10,12,14 is then cooled, or permitted to cool, at that second pressure until the temperature of the laminate 10,12,14 falls to the intermediate temperature, at which time
  • the resulting laminate 10,12,14 can be bent to conform to a variety of shapes.
  • cold bending can be used to achieve gentle bend radii.
  • the invention contemplates the application of heat prior to bending to thereby achieve a secondary forming temperature of perhaps about 160°F to about 180°F, using a line bender or other suitable equipment will permit the localized bending of the laminate without delamination of the constituent layers.
  • the bent laminate is annealed, for example, using a blanket or warming room, to reduce spring-back due to memory effect.
  • thermoplastic laminates 10,12,14 can be further vacuum thermoformed or pressure thermoformed onto a variety of pre-formed substrates.
  • the thermoplastic laminates 10,12,14 of the invention can also be sawn, routed, drilled, and otherwise machined in order to shape the laminate for the intended use.
  • the interfaces between the several constituent sheets of a given layer continue to define an interface between these bonded sheets after hot pressing.
  • These interfaces cause discontinuities that advantageously serve to bridge surface imperfections to thereby significantly reduce "telegraphing" of substrate surface imperfections when the resulting laminate is applied as a veneer to a pre-formed substrate.
  • thermoplastic laminates of the invention are suitable for a wide variety of applications and uses, including without limitation, as a covering over wood or other material to provide a functional and or decorative cover or stand alone decorative panel or partition, or be installed in a frame.
  • the thermoplastic laminates of the invention can be attached to wood, MDF, or other suitable substrates using a suitable adhesive.
  • the thermoplastic laminates of the invention can also be used in the furniture industry where the flexible laminate will be used to cover and provide a pleasing exterior to cabinet bases, doors, drawers, tables, other articles of furniture.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Abstract

Un stratifié thermoplastique comporte une couche supérieure; ou 'feuille capuchon' doit d'un premier matériau en PVC sur lequel est appliqué une fine couche dure pour la résistance aux rayures, soit d'une ou de plusieurs feuilles acryliques, de préférence, modifiées afin de leur conférer une résistance à l'impact. Immédiatement sous la couche supérieure se trouve une première couche de polycarbonate afin d'améliorer la résistance à l'impact et une résistivité chimique élevée, et une feuille de placage de bois décorative formant une couche image pour le stratifié. Une couche de fond est formée d'une ou de plusieurs feuilles, soit d'une seconde couche de polycarbonate, d'un second matériau de PVC (pouvant être le même que le premier matériau en PVC), ou d'un matériau en ABS. Des couches adhésives sont disposées entre les couches première, intermédiaire; seconde intermédiaire et de fond. La couche de fond est de préférence formée de plis multiples, d'une épaisseur de feuilles, liés les uns aux autres lorsque les couches empilées du stratifié sont pressées à chaud.
PCT/US2003/028795 2002-09-12 2003-09-12 Structure de stratifie thermoplastique avec coeur en placage de bois WO2004041534A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003272364A AU2003272364A1 (en) 2002-09-12 2003-09-12 Thermoplastic laminate structure with a wood veneer core

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US41010702P 2002-09-12 2002-09-12
US60/410,107 2002-09-12

Publications (1)

Publication Number Publication Date
WO2004041534A1 true WO2004041534A1 (fr) 2004-05-21

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007098361A2 (fr) * 2006-02-17 2007-08-30 Lighthouse Advanced Materials Group, Inc. Structure stratifiee adaptee aux exterieurs de meubles
US7923477B2 (en) 2006-01-20 2011-04-12 Material Innovations Llc Carpet waste composite
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US9073295B2 (en) 2008-12-19 2015-07-07 Fiber Composites, Llc Wood-plastic composites utilizing ionomer capstocks and methods of manufacture
CN105171854A (zh) * 2015-08-05 2015-12-23 南京林业大学 一种炭化阻燃杨木复合板
US11572646B2 (en) 2020-11-18 2023-02-07 Material Innovations Llc Composite building materials and methods of manufacture

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US9637920B2 (en) 2006-01-20 2017-05-02 Material Innovations Llc Carpet waste composite
US10294666B2 (en) 2006-01-20 2019-05-21 Material Innovations Llc Carpet waste composite
US7923477B2 (en) 2006-01-20 2011-04-12 Material Innovations Llc Carpet waste composite
US11773592B2 (en) 2006-01-20 2023-10-03 Material Innovations Llc Carpet waste composite
US8278365B2 (en) 2006-01-20 2012-10-02 Material Innovations Llc Carpet waste composite
US8455558B2 (en) 2006-01-20 2013-06-04 Material Innovations Llc Carpet waste composite
US10822798B2 (en) 2006-01-20 2020-11-03 Material Innovations Llc Carpet waste composite
US8809406B2 (en) 2006-01-20 2014-08-19 Material Innovations Llc Carpet waste composite
WO2007098361A2 (fr) * 2006-02-17 2007-08-30 Lighthouse Advanced Materials Group, Inc. Structure stratifiee adaptee aux exterieurs de meubles
WO2007098361A3 (fr) * 2006-02-17 2008-03-06 Lighthouse Advanced Materials Structure stratifiee adaptee aux exterieurs de meubles
US9073295B2 (en) 2008-12-19 2015-07-07 Fiber Composites, Llc Wood-plastic composites utilizing ionomer capstocks and methods of manufacture
US10875281B2 (en) 2008-12-19 2020-12-29 Fiber Composites Llc Wood-plastic composites utilizing ionomer capstocks and methods of manufacture
WO2012087097A1 (fr) * 2010-12-21 2012-06-28 Intempo Sistemas Constructivos S.A. De C.V. Feuilles polymères thermiques en pvc à haute résistance
CN105171854A (zh) * 2015-08-05 2015-12-23 南京林业大学 一种炭化阻燃杨木复合板
US11572646B2 (en) 2020-11-18 2023-02-07 Material Innovations Llc Composite building materials and methods of manufacture

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